Battery Cell Tab Assembly With Soldered Interlocking Connection
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Solution Overview
Problem
Existing battery cell assemblies face challenges in efficiently coupling electrode tabs and lead tabs to form a reliable charge-discharge path, particularly in high-output and high-capacity applications such as electric vehicles.
Innovation Solution
The battery cell assembly incorporates a novel structure where the electrode tab and lead tab are coupled using soldering material, with specific arrangements of solid portions and openings or convex and concave portions to enhance the electrical connection and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding or bonding processes are used to couple electrode tab and lead tab, then electrical connection reliability is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent replaces welding or bonding processes with a mechanical coupling structure. The lead tab includes a coupling portion with a through hole that mechanically receives and secures the electrode tab, eliminating the need for thermal or chemical joining processes while maintaining electrical connection reliability.
Solution Approach 2:
The coupling portion of the lead tab acts as an intermediary mechanical structure that joins the electrode tab to the battery cell body. This intermediate coupling mechanism provides a reliable connection without requiring direct welding or bonding between the electrode tab and lead tab.
2Reliability
If solid portions and openings or convex and concave portions are arranged alternately in the tab structure, then mechanical stability and electrical connection are improved, but device complexity increases
Solution Approach 1:
The lead tab is segmented into multiple solid portions and openings arranged alternately along its length. This segmentation creates multiple contact points and mechanical interlocking features with the electrode tab, improving both mechanical stability and electrical connection while distributing stress across multiple locations.
Solution Approach 2:
The alternating solid portions and openings create local variations in the tab structure, with solid portions providing mechanical strength and electrical contact, while openings provide spaces for soldering material or mechanical interlocking. This local differentiation optimizes both mechanical and electrical properties at specific locations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures a secure and efficient electrical connection between the electrode tab and lead tab, supporting high-output and high-capacity applications while reducing the need for costly bonding processes like welding.
Implementation Method 1
a soldering material coupling the electrode tab and the lead tab to each other
Data Source
AI summary
A battery cell assembly includes: a battery cell including a battery cell body and an electrode tab extending from the battery cell body in a first direction; a lead tab at least partially overlapping the electrode tab in the first direction and coupled to the electrode tab to provide an electrical connection therebetween; and a soldering material coupling the electrode tab and the lead tab to each other. At least one of the electrode tab and the lead tab includes: solid portions and openings that are alternately arranged in the first direction, or convex portions and concave portions that are alternately arranged in the first direction, and the soldering material is between adjacent ones of the solid portions or between adjacent ones of the convex portions.